Electric coupler

ABSTRACT

An electrical coupler unit includes a plurality of wafers which are stacked so that open slots of each of the wafers form contactor-receiving cells with associated portions of flat surfaces of adjacent wafers. A plurality of contactors are inserted into and locked within the cells formed by the stacked wafers and are formed with pockets for supporting the ends of associated conductors which are soldered thereto. Mating coupler units are assembled within supporting bands to facilitate the connecting of mating contactors of the units to form an electrical coupler.

United States Patent Inventor Vincent A. Rayburn Baltimore, Md. Appl.No. 817,866 Filed Apr. 21,1969 Patented Sept. 14, 1971 Assignee WesternElectric New York, N.Y. Continuation-impart of application Ser. No.418,995, Dec. 17, 1964, now Patent No. 3,457,640.

ELECTRIC COUPLER 30 Claims, 28 Drawing Figs.

US. Cl 339/49, 339/113, 339/176, 339/198, 339/217 Int. Cl H0lr 25/00Field of Search 3 39/49,

[56] References Cited UNITED STATES PATENTS 2,546,854 3/1951 Foster eta1. 339/113 L X 3,005,180 10/1961 Dreher 339/l98.4 3,036,287 5/1962Dierks"- 339/198 X 3,112,974 12/1963 Curtis et al. 339/49 3,173,7343/1965 Hartwell 339/49 3,178,669 4/1965 Roberts 339/49 PrimaryExaminer.lames A. Leppink Assistant ExaminerTerrell P. Lewis AltomeysH.J. Winegar, R. P. Miller and Don P. Bush ABSTRACT: An electrical couplerunit includes a plurality of wafers which are stacked so that open slotsof each of the wafers form contactor-receiving cells with associatedportions of flat surfaces of adjacent wafers. A plurality of contactorsare inserted into and locked within the cells formed by the stackedwafers and are formed with pockets for supporting the ends of associatedconductors which are soldered thereto. Mating coupler units areassembled within supporting bands to facilitate the connecting of matingcontactors of the units to form an electrical coupler.

PATENIED-sEP I 4 I97! 3.605.068

sum 1 0F 9 INVENTOR.

A. RAYBURN O ATTORNEY PATENTEU SEP 1 4 l9?! SHEET 2 OF 9 PATENTEU SEPI 4I97! SHEET t 0F 9 PATENTED SEP I 4 Ian SHEET 7 OF 9 FIG. 20

w 2 a T 2 m) j 7 0 B W 2 0 M M w m M L m, I B r B 2 F. 23 3 2 k 6 w 4 BPATENTEU SEPI 419m SHEET 8 UF 9 ELECTRIC COUPLER This in acontinuation-in-part of application Ser. No. 418,995, filed Dec. I7,I964, now US. Pat. No. 3,457,640, issued July 29, I969.

BACKGROUND OF THE INVENTION 1. Field of the Invention This inventionrelates to an electrical coupler and particularly to a symmetrical,laminate, color-coded coupler.

2. Description of the Prior Art A standard color-coded telephone cableis described in US. Pat. No. 3,031,524, issued in the name of W. T.Hicks on Apr. 24, I962, and discloses in one embodiment a single unitcable consisting of 25 distinctive pairs of conductors. In manyinstances, multiples of such unit cables are combined to form a multipleunit group, wherein each unit cable is lashed with a pair of differentcolored binder tapes. In addition, the colorcode combination of eachpair of binder tapes for respective unit cables are formed from adifferent color combination relative to the remaining pairs ofcolor-coded binder tapes wrapped about the remaining unit cables. Inthis manner, the respective unit cables of a multiple unit group areclearly distinguishable from the remaining unit cables of the group. Theunit cables and the multiple unit groups are thereafter utilized forinterconnecting a plurality of subscriber sets with central officefacilities. Presently, the cable is manufactured and delivered to aninstallation group for installing the cable in either aerial orunderground conduits and for hand splicing individual cables or othertypes of terminations.

With the increasing volume of subscriber service in the telephony field,considerable time and effort is required by an installation group tohand splice the conductors of the cables for connection with othercables or terminations. Additional effort is necessitated to insureproper connection between similarly color-coded twisted pairs of unitcables being connected together as well as to insure the connecting ofunit cables having the same color-coded binder tapes wherein the unitcables form portions of separate multiple unit groups. Hence, a need forsimplifying and hastening cable connecting and terminating operations isapparent, wherein the color coding must be retained.

Additionally, where the cable is installed in conduits, couplingfacilities must be sufficiently compact to permit pulling them throughsuch conduits.

SUMMARY OF THE INVENTION It is, therefore, an object of the invention toprovide a new and improved compact multiple-contact coupler forsimplifying and hastening cable connecting and terminating operations.

Another object of the invention is the provision of a new and improvedmultiple-contact, color-coded, laminated coupler for connectingcorresponding unit cables while maintaining color identificationthroughout.

Still another object of the invention is the provision of a new andimproved multiple-contact, laminated, color-coded coupler havingdifferent colored wafers corresponding to a color code used with a cableto facilitate interconnecting colorcoded cables.

A further object of the invention is the provision of a new and improvedmultiple-contact, laminated coupler having wafers supported within aband with contactor protecting structure.

A still further object of the invention is the provision of a new andimproved multiple-contact, laminated coupler having wafers andcontactors which cooperate structurally to lock the contactors withassociated wafers.

An electrical coupler illustrating certain principles of the inventionmay include a pair of identical coupler units each having a plurality ofwafers held in a laminated stack for supporting a plurality ofcontactors assembled therewith. The wafers can be of different colorsand can be assembled in a coded array to match a color code scheme ofinsulation of conductors which are assembled with contactors supportedin similarly colored wafers.

The wafers may be supported in a resilient band and are formed withstructure which complements the formed structure of the contactors sothat the contactors are attached securely with the associated wafers topreclude undesirable disassembly of the contactors from the wafers whenthe wafers are not assembled in the laminated stack. The complementarystructure of the contactors and the wafers also facilitates theretaining of the contactors in a desired orientation when the associatedwafers are assembled in the laminated stack to form the coupler unit.

Other objects and advantages of the invention may be readily understoodfrom the following detailed description of a specific embodiment thereofwhen read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing acoupler which forms one embodiment of the invention and which includes apair of symmetrical coupler units assembled with a band for aligning andholding the coupler units in mating engagement;

FIG. 2 is an exploded perspective view showing the relationship betweenthe pair of mating coupler units of the coupler and the aligning andlocking band;

FIG. 3 is a perspective view showing structural features of one of apair of side wafers of the laminated coupler unit;

FIG. 4 is a partial end view, taken along line 4-4 of FIG. 3, showing akeeper notch formed in the side wafer;

FIG. 5 is a partial sectional view, taken along line 5-5 of FIG. 3,showing a structural recess formed in the side wafer to provide a gripfor facilitating manual removal of the laminated coupler unit fromwithin the band and for further reducing the effects of heat sink duringplastic molding of the side wafer;

FIG. 6 is a perspective view showing an intermediate wafer of thelaminated coupler unit;

FIG. 7 is a partial end view, taken along line 7-7 of FIG. 6, showing akeeper notch formed in the intermediate wafer, and further showing akeeper lug which cooperates with the notch of the adjacent intermediatewafer for facilitating cooperative positioning, aligning and locking ofthe wafers in a stacked, laminated configuration;

FIG. 8 is a sectional view, taken along line 88 of FIG. 6, showingstructural recesses of the intermediate wafer;

FIG. 9 is a perspective view showing the structural features of a secondof the pair of side wafers of the laminated coupling unit;

FIG. 10 is a partial end view, taken along line l0l0 of FIG. 9, showinga keeper lug of the side wafer shown in FIG. 9',

FIG. II is a partial perspective view of a metal strip showing the majorsteps of blanking and forming a contactor from the strip;

FIG. 12 is a partial perspective view of a plurality of formedcontactors bent downwardly and held in a spaced relation by a backbonestrip supported by a skeleton rib;

FIG. 13 is a partial perspective view showing the contactors held in aspaced relation by the crimped backbone strip to facilitate a moreclosely aligned spacing between adjacent contactors;

FIG. 14 is a perspective view showing a single insulated conductorsecured with a contactor;

FIG. I5 is a closed end view of a disposable dust cover which isinserted into one end of a band having a coupler unit inserted into theother end and is used to protect tines of coupler contactors duringshipment;

FIG. I6 is a perspective view taken along line I6l6 of FIG. 55 showingan open end view of the dust covers;

FIG. I7 is a partial sectional view of the contactors assembled in cellsof the coupler unit;

FIG. 18 is a partial sectional view taken along line 18-18 of FIG. 1showing opposed coupler units of a coupler in mating arrangement,whereby a five-point contact is established between each of the matingpairs of contactors;

FIG. 19 is a diagrammatical view showing the location of color-codedtwisted pairs of conductors relative to associated contactor-receivingcells of the coupler unit as viewed from the contact side of the unit;

FIG. 20 is a perspective view showing an alternative embodiment of thecoupler which includes a pair of symmetrical coupler units eachassembled within an associated inner band and further assembled withinan outer band for aligning and holding the coupler units in matingengagement;

FIG. 21 is a side view showing an intermediate wafer of the laminatedcoupler unit shown in FIG. 20;

FIG. 22 is a sectional view taken along line 22-22, of FIG. 21, showingstructural recesses and a contactor locking slot of the intermediatewafer shown in FIG. 21;

FIG. 23 is a perspective view showing one of the contactors assembled inan associated slot of the intermediate wafer shown in FIG. 21;

FIG. 24 is a perspective view showing structural features of one of apair of side wafers of the laminated coupler unit shown in FIG. 20;

FIG. 25 is a perspective view showing structural features of a second ofthe pair of side wafers of the laminated coupler units shown in FIG. 20;

FIG. 26 is a perspective view showing the inner band for supporting thewafers in a laminated stack and showing structural features forprotecting exposed portions of contactors extending from the stackedwafers;

FIG. 27 is a perspective view showing the outer band for supportingmating coupler units therein in the forming of the coupler shown in FIG.20, and

FIG. 28 is a perspective view showing a shipping cover inserted into oneend of the outer band of FIG. 27 and onto portions of the inner band ofFIG. 26 with portions of the inner and outer bands shown in phantomview.

DETAILED DESCRIPTION Referring to FIGS. 1 and 2, there is illustrated acoupler, designated generally by the numeral 20, which forms anexemplary embodiment of the invention. The coupler 20 includes a pair ofidentical, laminated, universally color-coded coupler units, designatedgenerally by the numeral 2], which are interlocked and subsequently heldtogether by a resilient, plastic band, designated generally by thenumeral 23. Each coupler unit 21 includes a plurality of differentcolored, plastic, intermediate wafers, designated generally by thenumeral 22, (FIG. 2) which are numbered 22a through 22e to designatethat each wafer is composed of a different color relative to the otherwafers such as blue, orange, green, brown and slate, respectively. Eachof the coupler units 21-2I is provided with a plurality of contactors,designated generally by the numeral 24, (FIG. 2) which are positionedfor mating engagement with the contactors of the opposing coupler unit.The coupler unit 21 may be used in connecting the ends of cables, suchas unit cables 26-26, wherein each cable is composed of a plurality oftwisted pairs of conductors 27-27 and is substantially similar to theunit cable described in US. Pat. No. 3,03 l ,524, issued to W. T. Hicks.

An example of the unit cable 26 would include 25 twisted pairs ofconductors 27-27, wherein each of the conductors is individuallyinsulated with a colored insulation material. Ten different pairingcolors of insulation material are utilized with two groups of five basecolors each, thereby composing 25 pairs of 50 conductors 27-27 whichform the unit cable 26. The base code colors to be utilized include afirst group of colors such as white, red, black, yellow and violet; anda second group of colors such as blue, orange, green, brown and slate.

TABLE I Pair Conductor Conductor Number A B I White Blue 2 White Orange3 White Green 4 White Brown 5 White Slate 6 Red Blue 7 Red Orange 8 RedGreen 9 Red Brown 10 Red Slate I l Black Blue I2 Black Orange 13 BlackGreen l4 Black Brown l5 Black Slate l6 Yellow blue 17 Yellow Orange 18Yellow Green I) Yellow Brown 20 Yellow Slate 2I Violet Blue 22 VioletOrange 23 Violet Green 24 Violet Brown 25 Violet Slate In accordancewith a pattern as shown in table I, a pair identification system isutilized wherein conductors A and B of each of the 25 pairs areinsulated with different colored insulation, with each pair having acolor combination different from any other color combination of theremaining pairs. In addition, it is to be noted that the base codecolors of the first group are utilized on the insulation of theconductors A and the base code colors of the second group are utilizedon the insulation of the conductors B.

Further, a pair of different-colored binder tapes (not shown) is wrappedhelically about each unit cable 26 which forms a portion of a multipleunit group comprising a plurality of unit cables. Hence, a given unitcable of 25 pairs of conductors 27-27 is distinguishable from theremaining unit cables of the group by having a different colorcombination of pairs of colored binder tapes wrapped helically aroundrespective unit cables of the group. The coupler units 2I-2l arecomposed of the different colored, intermediate wafers 2222 preassembledbetween a pair of different colored, plastic, side wafers, designatedgenerally by the numerals 28 and 29, wherein the colors utilized in theintermediate wafers 22a through 22e conform to the colors used in theinsulation of the second group of base code colors such as blue, orange,green, brown and slate, respectively, and the colors of the side wafersconform to the colors of the pair of colored binder tapes wrappedhelically around the unit cable 26. In this manner, one unit cable 26 of25 pairs of conductors 27-27 is readily distinguishable from an adjacentunit cable of 25 pairs by observing the different color combination ofthe side wafers 28 and 29 of the coupler unit 21.

As viewed in FIGS. 6 through 8, I7 and I8, each of the individual,intermediate wafers 2222 is generally of a flat and rectangularconfiguration and is formed with a fiat face 30 on one major surfacethereof and on the opposite major surface with spaced, parallel slots 31which transverse the short dimension of the rectangular wafer. Each slot31 is formed with opposed, spaced sidewalls 32-32 with a flat bed 33contiguous with and extending between the walls for receiving thecontactor 24. A common end of each of the beds 33-33 of the wafer 22 isformed with a downwardly sloped surface 34.

The opposite common ends of each of the beds 33-33 of the wafer 22 isformed with a transverse undercut 36 with an upwardly sloped surface 37extending outwardly therefrom. It is noted that the sloped surface 34and the undercut 36 facilitate the self-securing of the contactor 24lengthwise within the slot 31 of the coupler unit 21. In addition, the

sloped surface 37 strengthens the walls of the slots 31-31 at the entryend and provides an insulator barrier between adjacent pairs ofcontactors 24-24 as well as a guide for an entering, mating connector.Keeper lugs 38 and 39 extend upwardlv from opposite ends of the flat,slotted surface 35 of the wafer 22, and conforming keeper notches 41 and42 are formed in the opposite ends of the other flat surface of thewafer 22 wherein the lugs cooperate with the conforming notches of anadjacent wafer 22 for locking the wafers together to preclude relativelateral sliding movement in any direction.

As further viewed in FIGS. 3, 4 and 5, the side wafer 28 issubstantially flat and rectangular with two major flat surfaces 55 and60. The wafer 28 is formed with through-notches 43 and 44 on oppositeends thereof to facilitate the reception of the keeper lugs 38 and 39 ofthe adjacent, intermediate wafer 22 to preclude relative lateral slidingmovement in any direction. In addition, the flat surface 55 of the sidewafer 28 is formed with a projection 46, which fits into a cutaway 47(FIGS. 1 and 2) of the band 23. The projection 46 of the side wafer 28is formed with a recess 48 to facilitate a grip for manual handling ofthe coupler unit 21 relative to the band 23 and also reduce undesirablestrain effects resulting from heat sink during the molding of thewafers.

The side wafer 28 is formed with a corner keyway 45 along the edge whichis provided with the through-notch 43 and cooperates with one of a pairof corner keys 50-50 (FIG. 2) formed along diagonally opposed corners ofa common inner wall of the band 23. It is noted that each of the keys50-50 extend into the band 23 from respective open ends of the bandapproximately one-half of the distance between the open ends of theband. Hence, as shown in FIG. 2, proper orientation of the matingcoupler units 21-21 prior to mating engagement is assured by thecooperation of the corner keys 50-50 on the inner wall of the band 23and the complementary keyways 45-45 of the side wafers 28-28. Properalignment of the mating couplers 21-21 is accomplished by the closesliding fit of the coupler units 21-21 with the band 23.

As viewed in FIGS. 9 and 10, the side wafer 29 is substantially flat,and is formed at opposite ends of one flat surface with projectingkeeper lugs 49 and 51 which are positioned within keeper notches 41 and42, respectively, of the adjacent, intermediate wafer 22, whereby theside wafer is assembled with the adjacent, intermediate wafer topreclude relative lateral sliding movement in any direction. The sidewafer 29 is also formed with a projection 52 extending from the oppositeflat surface, wherein the projection is formed with a recess 53 forfacilitating handling of the coupler unit 21 relative to the band 23 andto reduce undesirable heat sink effects.

As the intermediate wafers 22a-22e and side wafers 28 and 29 areassembled in a laminated stack, the flat face 30 of one wafer ispositioned adjacent the slotted surface 35 of the adjacent wafer,whereby the slots 31-31 are enclosed to define contactor-receivingcells, designated generally by the numeral 54, as shown in FIGS. 2, 17and 18. In addition, the flat surface 60 of the side wafer 28 cooperateswith the adjacent, intermediate wafer 22 to enclose the slots 31-31 ofthe intermediate wafer, thereby forming contactor-receiving cells 54- 54with predetermined spacing between adjacent cells. Further, the cells54-54 are displayed in individual rows formed by each wafer 22 as wellas perpendicularly disposed columns formed by the combination of waferswhere the columns are denoted by Roman Numerals I through X as shown inFIG. 19.

Thus, by forming the wafers 22-22 of the laminated stack with the keeperlugs 38 and 39 and the keeper notches 41 and 42, each wafer of thelaminated assembly is precluded from lateral sliding movement relativeto the remaining wafers. The projection 46 formed on the outer surfaceof the side wafer 28 and the projection 52 formed on the outer surfaceof the opposite side wafer 29 provide hand grips to facilitate manualmovement of the mating coupler units ZI-Zl relative to the band 23. Theouter end walls of the projections 46 and 52 are rounded and arrangedfor interference engagement with the inner end walls of the cutaways47-47, thus providing friction fits to hold the mating coupler unitstogether within the band 23.

Generally the miniature contactors 24-24 are stamped from a stock stripin transverse multiples held on backbone cross strips supported bycontinuous stock side strips to facilitate handling of the miniatureparts through subsequent necessary operations. Without'this supportedhandling, the contactors 24-24 would tangle and mat together so thatlater separation would be tedious, time-consuming, injurious to thecontactors and prohibitively expensive.

The backbone cross strips and the continuous stock side strips cooperateto provide means for holding the contactors 24-24 in suspended,parallel, spaced relationship while tines of the contactors are tin orgold plated. The backbone strips and continuous side strips provide anelectrical path for the plating operation, and plate metal is conservedby plating only the contact end of the contactors.

The securing of the conductors 27-27 to the contactors 24-24 isfacilitated by a soldering operation which is greatly facilitated withmultiple contactors held in spaced relation on the backbone strip.Placement of the contactors 24-24 in a soldering device is much fasterand more precise while layup of the color-coded conductors 27-27 of theunit cable 26 is simplified, and a plurality of the contactors held by asingle backbone strip can be soldered simultaneously to respective cableconductors.

A coupler unit 21 embodying the features of the invention may be easilyconnected to conductors 27-27 at the extremities of a unit cable 26 atthe manufacturing location, wherein the cable is wound on a reel andsubsequently delivered to an installation group in the field forinstalling the cable in telephone distribution networks. With the aid ofsuch a colorcoded coupler unit 21, an installer need only insert thecoupler unit connected to the trailing end of a cable 26 of a depletedsupply reel to the mating coupler unit connected to the leading end of acable of a new supply reel in accordance with the aligned colors of thecolored, laminated wafers 22- 22. This procedure obviates thetime-consuming task of handsplicing the individual conductors of onecable to the individual conductors of another cable.

Where unit cables 26-26 are combined to form a multiple unit group, sidewafers 28 and 29, which are positioned at the opposite sides of thelaminated wafer stack of the coupler unit 21, connected to a given unitcable, are composed ofa colored material corresponding to the colors ofthe respective pair of binder tapes wound helically around the givenunit cable. In addition, the method of fabricating and inserting thecontactors 24-24 into the coupler units 21-21 at the manufacturinglocation requires considerably less time than is required for thehand-splicing operation by the installer in the field. Thus, the overalltime required for the connecting operation is greatly reduced by theutilization of the coupler 20 and the method of fabrication of thecoupler and effectively reduces associated time delays to customerservice.

Specifically, the contactors 24-24 (FIG. 2), which are utilized in thecoupler unit 21 are stamped from an elongated metal strip 56, as shownin FIG. 11, wherein the strip is provided with a series of perforations57-57 along the border edges thereof to receive means for moving andaligning the strip during subsequent blanking and forming steps. As thestrip 56 is guided through a punching press (not shown), the strip ispunched transversely into a plurality of patterned blanks, generallydesignated by the reference numeral 58. Each blank 58 is formed with along tine 59 and a short tine 61 bridged at their heel ends by a centralweb section 62 which holds the tines in parallel, cantileverrelationship. A tab 63 extends from the central web section 62 spatiallybetween the tines 59 and 61.

At the opposite end of the web section 62, a rib strip 64 connects thepatterned blank 58 to a commonly supporting, transverse backbone strip66. Further, a tab 67 extends rearwardly from the short tine 61spatially adjacent the rib strip 64. The rib strip 64 is scored at 68near the web 62 for subsequent removal of the individual contactors24-24 from the rib strip and the backbone strip 66. A plurality ofbackbone strips 66- 66, each supporting a plurality of spaced patternedblanks 58-58, are spatially formed from the strip 56 and are supportedby and extend transversely between spaced skeleton side strips 69-69(one shown).

The side strips 69-69 with the blanks 58-58 and the backbone strips66-66 are subsequently fed into forming dies (not shown), wherein thelong tine 59, the tab 63 and the short tine 61 with the tab 67 of eachcontactor 24 are bent upwardly, as shown in FIG. 11, to form a pocket,designated generally by the numeral 72, in the area of the web section62 for reception of an exposed end of one of the conductors 27- 27.Thus, the long and short tines 59 and 61 extend integrally fromsidewalls of the pocket 72. in addition, each of the long tines 59-59 iscrimped slightly to form an intermediate ramp 73, while each of theshort tines 61-61 is formed at the free end thereof with a hooked ramp74. The rearward tab 67 is bent outwardly away from the neck portion 64and angularly extends from he pocket sidewall which is integral with theshort tine 61.

Subsequently, as viewed in FIG. 12, the side strips 69-69 with theformed contactors 24-24 and the backbone strips 66-66 are positionedwithin a bending die (not shown), wherein the rib strips 64-64supporting the formed contactors are bent downwardly at a right anglerelative to the backbone strips. The side strips 69-69 are moved into aplurality of stations (not shown) whereat the backbone-held contactors24-24 are degreased and cleaned, heat treated, pickled and gold-plated,and washed and dried to greatly increase the resiliency and fatigue lifeof the contactors and improve electrical contact.

The side strips 69-69 with the formed, downwardly suspended contactors24-24 are then passed into a crimping and cutting press (not shown),wherein the backbone strip 66 is crimped, as shown in FIG. 13, in areas76 between each of the spatially supported contactors, thereby reducingthe spacing between adjacent contactors. The reducing of the spacingbetween the contactors 24-24 is necessary to facilitate a subsequentsoldering operation and insertion of the contactors into the preciselyspaced cells 54-54 of the coupler unit 21. The backbone strips 66-66 aresequentially severed from the skeleton side strips 69-69 and the freebackbone strips are successively and automatically directed into acompartmented container (not shown) to facilitate handling andtransporting of the backbone-supported, miniature, fragile contactors24- 24 into a soldering station where the cable conductors 27-27 areassembled and secured with the contactors. The magazining of thebackbone-supported contactors 24-24 into containers minimizes damage to,or mutilation of, the miniature contactors during the handling andtransportation thereof.

The backbone-held contactors 24-24 are positioned and held in asoldering and cutting apparatus (not shown), such as that disclosed in acopending application in the name of H. E. Brent, Ser. No. 4l9,l32,which was filed on Dec. 17, 1964, now US. Pat. Nov 3,252,644 and issuedon May 24, 1966, wherein a plurality of the conductors 27-27 of the unitcable 26 are assembled and held in the pockets 72-72 formed by the tines49 and 51 and the tab 53. Thereafter. the pockets 72-72 are heated andindividual solder strands (not shown) are inserted into each respective,heated pocket 72, whereby the solder melts upon engagement with thepocket. Upon cooling of the solder, the conductors 27-27 are securedwithin the respective contactor pockets 72-72 by a solidified solder 77(FIGS. 14, 17 and 18). By depositing the cold solder directly into theheated pockets 72-72, the solder is prevented from forming on the outersurfaces of the pockets which could subsequently interfere with theclose fit of the contactor 24 within the cells 54-54 of the couplerunits 21- 21 and also undesirably bridge adjacent contactors.

Subsequent to the soldering operation, the apparatus automatically andtransversely severs the backbone strip 66 into selected segments witheach segment supporting five contactors 24-24. Hence, a unit cable 26 of25 conductor pairs would be secured with 10 backbone segments with eachsegment supporting five contactors 24-24 having five respectiveconductors 27 -27 secured therewith.

The conductors 27-27 are soldered to the contactors 24- 24in accordancewith the previously discussed color-code arrangement, whereby each ofthe conductors which form a twisted pair is soldered to contactors whichare subsequently secured in adjacent cells 54-54 of thecontactor-supporting coupler unit 21. Thereafter, the backbone-heldcontactors 24-24, having the paired conductors 27-27 'of the unit cable26 secured thereto, are inserted into and self-secured within the cells54-54 of the contactor-supporting coupler unit 21 where the hooked ramp74 initially engages the sloped surface 34 to facilitate flexing of theshort tine 61 during the insertion procedure.

The spacing between adjacent cells 54-54 of the coupler unit 21 isdetermined by the spacing of the wafer slots 31-31 which is small due tothe miniature size of the coupler unit. in the formation of thecontactors 24-24, sufficient material must be provided between adjacentcontactor blanks 58-58 (FIG. 11) to facilitate the formation of thecontactor elements. However, the necessary spacing between adjacentblanks 58-58 is greater than the critical spacing between adjacent cells54-54. Hence, the necessity for crimping the backbone strip 66 in theareas 76 (FIG. '13) is to reduce the spacing between the formedcontactors so that the contactor spacing coincides with the cell spacingto facilitate the gang insertion of the contactors into the coupler unitcells 54-54.

TABLE 2 Conductor Color Contactor Nam?" Segment Number m-rovubuw- VllTABLE 3 contactor Number Segment Number Conductor Color Violet VioletViolet l Violet Violet Slate Brown Green Orange Blue Yellow Y cllowYellow Yellow Y ellow Slate TABLE 3 Continued Brown Green Orange BlueBlack Black Black V Black Black The backbone strip 66 supports, forexample, 25 contactors 24-24 in the manner as shown in FIG. 13. A methodof assembling the conductors 27-27 of the 25 color coded, twisted pairsof the unit cable 2 with the contactors 24-24 includes holding thebackbone strip 66 to facilitate assembly and soldering of the individualconductors within the pockets 72-72 of the contactors. As displayed intable No. 2, numbers l through 25 have been assigned to the 25successive contactors 24-24, held by the common backbone strip 66, whichare assembled with a first group of 25 respective conductors 2727 of the50-conductor unit cable 26 in accordance with the pattern as outlined inthe table No. 2.

ln this manner, the five contactors 24-24 of each of three groups havingcontactors which are numbered I through 5, l 1 through and 21 through 25are assembled with conductors having colored insulation of the secondgroup of colors; namely, blue, orange, green brown and slate,respectively. The five contactors 24-24 numbered 6 through 10 areassembled, respectively, with the five conductors 2727 having whitecolored insulation. The remaining five contactors 24-24 numbered 16through 20 are assembled, respectively, with the five conductors havingthe red colored insulation. A second group of conductors 27-27 of the50-conductor unit cable 26 are assembled with the contactors 24-24 heldby another backbone strip 66 in accordance with the pattern as shown intable No. 3 wherein the number assignment and color scheme follows asimilar pattern as that described for table No. 2.

Subsequent to the assembly of the first 25 conductors 27- 27 with thecontactors 24-24 in accordance with the pattern shown in table No. 2,the conductors are secured within the individual pockets 72-72 of therespective contactors. It is noted that contactors 24-24, which arenumbered 1 and 6, are assembled with the conductors 27-27 which form theblue-white conductor pair; the contactors numbered two and seven areassembled with the orange-white conductor pair; the contactors numberedthree and eight are assembled with the green-white conductor pair and soon. Further, the contactors 24-24, which are numbered 11 and 16, areassembled with the blue-red conductor pair; the contactors numberedtwelve and seventeen are assembled with the orange-red conductor pairand so on.

As previously discussed, another backbone strip 66 supports the secondgroup of 25 contactors 24-24 wherein the contactors are numbered 26through 50 and are assembled with the remaining 25 conductors 2727 ofthe 50-conductor unit cable 26 in the manner as set forth in table No.3. It is noted that the conductors 27-27, which are assembled with thecontactors 24-24 numbered 2] and 26 in tables 2 and 3, respectively,form the blue-black pair; the conductors assembled with the contactorsnumbered 22 and 27 form the orange-black pair and so on. Further, theconductors 2727 assembled with the contactors 24-24 numbered 31 and 36in table No. 3 form the blue-yellow pair, and so on; while theconductors assembled with the contactors numbered 4i and 46 in table No.3 form the blue-violet pair, and so on.

Subsequent to the assembly f the 50 conductors 2 7-2 7 of the unit cable26 with the contactors 24-24 numbered 1 through 50 in accordance withthe pattern shown in tables 2 and 3, the backbone strips 66-66supporting the two groups of 25 contactors are each transversely severedalong four spaced planes to provide ten backbone supported segmentsdesignated by Roman numerals I through X in tables 2 and 3 wherein eachsegment supports five contactors with the conductors assembled andsecurcd therewith. For example, the segment I of five assembledconductors 27-27 and contactors 24-24 includes the contactors numbered46 through 50 having the conductors with violet colored insulationsecured therewith. As a further example, the segment ll of fivebackbone-supported, assembled conductors 27-27 and contactors 24-24includes the contactors numbered 41 through 45 assembled and securedwith conductors having blue, orange, green, brown and slate coloredinsulation, respectively. This segment pattern is continued as shown intables 2 and 3.

Referring to tables No. 2 and 3, the backbone-supported segment I,supporting the five contactors 24-24 numbered 46 through 50 which aresecured with the conductors having the violet colored insulation, isaligned with the column l of cells 54-54 which is the first column fromthe right of the coupler unit 21 as viewed in FIG. 19. The segment I ismoved toward the coupler unit 21 so that the contactors 24-24 areinserted into the cells 54-54 of the column I in such a manner that thebackbone strip of the segment projects to the left as viewed in FIG. 19and is substantially parallel with the face of the conductor side of thecoupler unit. Subsequent to the insertion of the contactors 24-24 of thesegment I into the cells 54-54 of the column I, the backbone strip ofthe segment I is flexed to separate the rib strips 64-64 from therespective contactors along the scored lines 68-68. I

The five contactors numbered 4l through 45 assembled with conductors27-27 having blue, orange, green, brown and slate colored insulation,respectively, and which are supported by the backbone segment ll, areinserted into the column ll of cells 54-54 which is the second columnfrom the right of the coupler unit 21 as viewed in FIG. 19. Thecontactors 24-24 of segment ll are assembled in the cells 54-54 of thecolumn ll in such a manner that the backbone strip of the segmentprojects to the left, as viewed in FIG. 19, parallel to the face of theconductor side of the coupler unit 21. By assembling the contactors24-24 of the segment ll in this manner, the backbone of the segmentprojects away from the previously assembled segment I rather thanprojecting between the assembled segments l and ll. Assembly of thesegments in this manner facilitates easy gripping and flexing of thesegment backbone to separate the rib strip 64 from the contactors 24-24along the scored lines 68-68. This assembly procedure precludes thenecessity of flexing the backbone of the segments between assembledsegments which could be cumbersome and difficult. In this manner, thefive contactors 24-24 of segment [1, which are assembled with conductorshaving blue, orange, green, brown and slate colored insulation, areinserted into the cells 54-54 of the column ll formed by theintermediate wafers 220 through 222 which are composed of the colorsblue, orange, green, brown and slate, respectively.

Thus, the contactor 24, which is numbered 4l in table No. 3, and whichis secured with the conductor having the blue insulation, is insertedinto the cell 54 which is coincident with the row of cells formed by theblue intermediate wafer 22a, and the cells formed by column ll; thecontactor numbered 42 which is secured with the conductor having theorange colored insulation is inserted into the cell which is coincidentwith the row of cells formed by the orange intermediate wafer 22b andthe cells formed by Column ll; the contactor numbered 43, is securedwith the conductor having the green insulation, is inserted into thecell which is coincident with the row of cells formed by the greenintermediate wafer 22c and the cells formed by Column ll, and so on.

Further the contactors 24-24 of the segments l and II are assembled inthe respective cells 54-54 of the columns I and ll in such a manner thatthe blue-violet pair of conductors 2727, which are secured to contactorsnumbered 4l and 46 (table No. 3), respectively, occupy adjacent cells ofthe row of cells formed by the intermediate blue wafer 22a. Theorangeviolet pair of conductors 2727 are secured to contactors 24-24,numbered 42 and 47 (table No. 3), respectively, which occupy adjacentcells 54-54 of the row of cells formed by the intermediate orange wafer22b. This pattern of assembly is followed with the remaining violetcolored conductor pairs. Further, the remaining segments III through Xare assembled with the coupler unit 21 in a similar pattern, wherebypairs of the contactors 24-24 secured with the respective pairedconductors 27-27 occupy adjacent coupler cells 54-54 of the rows ofcells formed by the respective, individual wafers 22-22 as shown in FIG.19.

In addition, it is noted that the pairs of conductors 2727, having oneconductor with blue insulation, are secured with contactors 24-24 whichare inserted into and occupy the cells 54-54 of the row of cells formedby the blue wafer 22a; the pairs of conductors having one conductor withorange insulation are secured with contactors which are inserted intoand occupy alternate cells of the row of cells formed by the orangewafer 22b, and so on. Further, each group of five conductors 2727 each,having insulation of the second group, namely, white, red, black, yellowand violet, respectively, are secured with contactors 24-24 which occupycells 54-54 in alternate columns of cells formed by the stacked rows ofcells not occupied by contactors secured to conductors having coloredinsulation of the first group.

Referring to FIG. 17, as each contactor 24 is inserted into one of thecells 54-54 of the coupler unit 21, the long tine 59 is moved throughand protrudes from the cell in a cantilever fashion. In addition, thehooked ramp 74 is flexed in the cell 54 and moves along the bed 33 ofthe cell until the free end of the hooked ramp engages and locks againstthe transverse undercut 36, thereby preventing rearward movement of thecontactor 24 within the cell. Further, the rearward tab 67 engages thesloped surface 34 to limit continued forward movement of the contactor24 within the cell 54. Thus, the contactors 24- 24 are positioned withinthe cells 54-54 and are prevented from slideable movement within thecells due to cooperative structural features of the contactors and thecoupler cells, whereby the contactors are located within the couplerunit 21 in a self-secured fashion. 1

As further shown in FIG. 17, the intermediate ramp 73 of the long tine59, urges the long tine upwardly against the wall of the cell 54 formedby the flat surface 30 of the adjacent wafer 22, thereby providingresiliency in the extended end of the tine which protrudes from thecoupler unit 21. This resilient feature aids in the subsequent flexingof the extend end of the tines 59-59 when the coupler unit 21 is matedwith another identical coupler unit.

It is noted that each of the contactors 24-24 can be removed from withinthe respective cell 54 by inserting a needlelike implement (not shown)into the contactor end of the cell, engaging the free end of the hookedramp 74 and thereafter lifting the ramp over the transverse undercut 36.The contactor 24 is thereafter withdrawn from the conductor end of thecell 54 by sliding the flexed tines 59 and 61 from within the cell andappears as shown in FIG. 14. This feature facilitates interchangeabilityof the contactors 24-24 necessitated by circuit changes and can beeffected at any location, for example, at the manufacturing facility orin the field.

Referring to FIG. 18, one of the contactor-supporting, assembled couplerunits 21-21 is inserted into one end of the band 23, whereby the closefit of the wafers 22-22 within the band facilitates alignment of thecontactors 24-24 of the coupler unit for subsequent mating engagementwith the contactors of the mating coupler unit. In addition, the couplerunit keyway 45 and the complementary band key 50 assure properorientation of the wafered coupler unit 21 as the unit is inserted intothe band 23 to mate with the identical coupler unit inserted from theopposite side of the band. The key 50 and keyway 45 precludes thepossibility of the coupler units 21-21 being inserted into the band 23in an incorrect orientation which could result in matting and tanglingof the mating contactors 24-24 possibly resulting in permanent damage.

As the pair of coupler units 21-21 are inserted into the band 23, thecantilevered long tines 59-59 of each contactor 24 of one coupler unitare inserted into the contactor end of opposing cells 54-54 between thespaced long and short tines 59 and 61 of the mating coupler unit andsubsequently engage and are flexed by the ramps 73 and 74 of thecontactors of the mating coupler unit. The engagement of thecantilevered ties 59-59 with the ramps 73 and 74 of the mating contactor24 flexes each of the tines into a substantially bow shape, whereby thetines 59-59 of one coupler unit engage the tines 59-59 of the matingcoupler unit at an intermediate portion thereof, thereby establishing afive-point contact between each pair of mating contactors of the couplerunits. In this manner, the contacting surfaces of the contactors 24-24establish a plurality of areas for contact, thereby insuring a goodelectrical connection.

Thus, the connecting of color-coded pairs of conductors 27-27 of onecable 26 with identically color-coded pairs of conductors of anothercable is readily accomplished by stacking the colored laminate wafers22-22 in a selected color-coded pattern to form the coupler units 21-21,inserting the conductor-supporting contactors 24-24 into cells 54-54 ofthe coupler unit in accordance with the previously discussed color-codearrangement, and thereafter mating the contactor-supporting couplerunits in such a manner that the colored wafers of one unit are alignedwith the mating unit wafers of the same colors.

Further, in the event the hooked ramp 74 of the short tine 61 is notcompletely resting within the undercut 36, the pressure exerted upon theramp by the long tine 59 of the entering mating contactor 24 issufficient to urge the ramp completely into the undercut as shown inFIG. 18. As the mating coupler units 21-21 engage, the coupler units arefrictionally held within the plastic band 23 (FIGS. 1 and 18) wherebythe laminated, intermediate wafers 22-22 and the side wafers 28 and 29are precluded from individual movement in any direction. It is notedthat the cantilevered end of each of the tines 59-59 is tapered inwardlyto facilitate the alignment of the contactors 24-24 as the contactorsenter into the cells 54-54 of the mating coupler unit 21.

Subsequent to the assembly of the contactors 24-24 within the couplerunit 21 and the further insertion of the coupler unit into one end ofthe band 23, the unit cable 26 and the respective coupler unit areprepared for shipment whereby a disposable dust cover, designatedgenerally by the numeral 78, as shown in FIGSv 15 and 16, is insertedinto the open end of the band 23. The cover 78 has a containerlike shapesuch as a plastic shell 79 with a closed end 81 where the outer shellconforms substantially to the outer configuration of the assembled,laminated coupler unit 21. The dust cover 78 is further formed withprojections 82-82 which protrude from opposite sides of the shell 79adjacent the closed end 81. Recesses 83- 83 are formed in the outerportion of the closed end 81 where the projections join the shell 79,thereby facilitating resilient gripping of the dust cover 78 and furtherreducing the effects of heat sink during molding of the cover. Inaddition, the dust cover 78 is formed with a keyway which iscomplementary with the band key 50 to facilitate insertion of the coverinto the band.

As the dust cover 78 is inserted into the open end of the band 23, theopen end of the shell 79 is guided about the cantilevered tines 59-59extending from the coupler unit 21 which is positioned in the oppositeopen end of the band, thereby protecting the tines from accidentalbending and damage during transportation of the assembled unit. Thearrangement of the dust cover 78 within the band 23 also provides asubstantially dust-free enclosure for the coupler unit elements, therebypreventing damage to and an accumulation of dust on the contactors24-24.

As noted, each coupler unit 21 is assembled within one end of the band23 with a dust cover 78 inserted into the other end. When the coupler 20is to be assembled in the field, an installer removes and discards thedust cover 78 from within the band 23 which supports the coupler unit 21assembled with the end of one of the cables 26-26. Thereafter, theinstaller removes from another band 23 the coupler unit 21 assembledwith the end of another cable 26 and inserts this coupler unit into theopen end of the first band for mating assembly with the coupler unit inthe opposite end of the band, thereby completing the coupling procedure.

While the conductor-supporting contactors 24-24 are assembled with thewafered coupler units 21-21 in the manner previously discussed, polingfrequently occurs wherein the colored wafers 22a-22e of one coupler unitdo not align with the corresponding colored wafers of the mating couplerunit when the coupler units are inserted into the band 23. This is anindication to the installer that the wafers 22a-22e of the coupler units21-21 are not properly oriented for accomplishing the desired couplingand that poling has resulted. In the event such poling occurs, theinstaller merely removes one of the coupler units 21-21 from within theband 23 and restacks the individual wafers 22a-22e relative to the sidewafers 28 and 29 to obtain the required wafer color alignment andthereafter inserts the reoriented coupler unit into the band 23 tofacilitate the desired coupling.

To facilitate reorientation of the wafers 220-222 for obtaining propercolor alignment, the installer selects one of the coupler units 21-21and separates the side wafer 29 from the remaining wafers. Thereafter,the installer carefully separates the first wafer 22, which was adjacentthe removed side wafer 29, and assembles the removed wafer 22 with aspare side wafer 28. It is noted that the contactors 24-24, which areassembled within the cells 54-54 formed by the removed wafer 22, willremain with the wafer, thereby retaining the desired contactor assemblyfor that row of cells. The next succeeding wafer 22 is removed from theoriginal stack and is assembled with the first removed wafer with theassembled contactors 24-24 remaining with the transferred wafer. Thispattern is continued until the wafers 22-22 of the removed coupler unit21 have been reoriented to facilitate proper color alignment of thewafers 22a-22e for proper mating with the other coupler unit 21 withinthe band 23. Hence, the wafer structure of the coupler units 21-21readily facilitates reorientation of the colored wafers 220-222 wheresuch reorientation is necessary to accomplish the desired coupling.

It is to be noted that the color-code arrangement and related numericaldesignations disclosed herein is merely representative of one of manycolors and numerical schemes which could be incorporated into such acolor-code system. Further, the coupler unit 21 can be easily modifiedto facilitate the reception of other combinations and numbers ofterminals and is thereby not limited to the arrangement disclosedherein.

Referring to FIG. 20, there is illustrated a coupler, designatedgenerally by the numeral 120, which forms an alternative embodiment ofthe invention. The coupler 120 includes a pair of identical, laminated,universally color-coded coupler units, designated generally by thenumeral 121. Each of the coupler units 121- 121 includes a plurality ofdifferent colored, plastic, intermediate wafers, designated generally bythe numeral 122. For the purposes of explanation, the wafers 122-122,which are shown in FIG. 20, have been numbered units 1220 through 122eto indicate that the wafers are colored blue, orange, green, brown andslate, respectively.

The wafers 1220 through 122e of each coupler unit 121 are assembled withplastic side wafers, designated generally by the numerals 128 and 129.The assembled wafers 122-122 and side wafers 128 and 129 are theninserted into an associated, resilient plastic, inner band, designatedgenerally by the numeral 123, which retains the wafers in compact,laminated arrangement. The coupler 120 can be utilized in the samemanner and has all of the previously described advantages of the coupler20 (FIG. 1) including all of the various color schemes, the preassemblyof the coupler units at the manufacturing locations and protection ofcoupler elements during shipment.

Each coupler unit 121 is provided with a plurality ofcontactor-receiving cells, designated generally by the numeral 154, forsupporting a plurality of contactors, designated generally by thenumeral 124, for mating engagement with a corresponding plurality ofcontactors of a mating coupler unit.

Each of the contactors 124-124 may be connected to an associated one ofa plurality of conductors 127-127 which form a portion of a cable, suchas the unit cable 26 (FIG. 1). The mating coupler units 121-121 areassembled within a resilient, plastic, outer band, designated generallyby the numeral 125, which retains the mating coupler units in theassembled relation. The conductors 127-127 may form twisted pairs withinthe unit cable 26 and have insulation in a color code scheme such asthat previously described with respect to US. Pat. No. 3,031,524. Theinsulated conductors 127-127 would then be assembled with associatedcontactors 124- 124 of the coupler units 121-121 formed by the coloredwafers 122a122e in accordance with the previously described color codescheme.

In addition, the side wafers 128 and 129 can be used in a color codescheme similar to that previously described wherein pairs of differentcolored binder types, which are wrapped helically about associated onesof a plurality of unit cables 26-26 of a multiple unit group, correspondto the colors of the side wafers 28 (FIG. 3) and 29 (FIG. 9) to idcntifythe unit cable to which a particular coupler unit 21 (FIG. 2) isconnected.

Referring to FIG. 21, there is illustrated one of the wafers 122-122which are similar to the wafers 22-22 (FIGS. 6, 7 and 8). Each of thewafers 122-122 is formed with two major surfaces 130 and 135. Aplurality of spaced, parallel slots, designated generally by the numeral131, are formed in he surface 135. Each of the slots 131-131 includes apair of spaced sidewalls 132 and 232 and a flat bed 133 which extendsbetween the base of the sidewalls.

As illustrated in FIG. 22, one end of the flat bed 133 of each of theslots 131-131 is formed with a sloped trailing surface 134. The otherend of the flat bed 133 of each of the slots 131-131 is formed with atransverse undercut 136 and a sloped forward surface 137. Referringagain to FIG. 21, each of the wafers 122-122 is formed with keeper lugs138 and 139 which project outwardly from opposite ends of the surface135. In addition, a pair of conforming keeper notches 141 and 142 areformed in opposite ends of the surface 130 of each of the wafers122-122. When the wafers 122-122 are assembled in a laminated stack toform the coupler unit 121, the keeper lugs 138 and 139 of each wafer fitinto the conforming keeper notches 141 and 142, respectively, of theadjacent wafer to prevent relative shifting of the stacked wafers in anylateral direction.

Referring again to FIG. 22, a portion of the wall 132 of each of theslots 131-131 is formed with a cutaway adjacent to the associated slopedsurface 134. A contactor-locking groove 145 is also formed in each ofthe walls 132-132 adjacent to a portion of the flat bed 133 and iscontiguous with the cutaway 140.

Referring now to FIG. 23, there is illustrated one of the contactors124-124 which is fonned in a manner similar to the forming of thecontactors 24-24 (FIG. 14), as previously described. Each of thecontactors 124-124 is formed with a long tine 159 and a short tine 161and with a web section 162 which is integral with and extends betweenrearward, adjacent portions of the long and short tines. A tab 163,which is integral with and extends from the forward end of the websection 162, is folded to a position transversely between intermediate,spaced portions of the long and short tines 159 and 161, respectively.The web section 162, the tab 163 and the rearward, spaced adjacentportions of the long and short tines 159 and 161, respectively, whichare contiguous with the web section, form a pocket, designated generallyby the numeral 172, for receiving the bared end of an associated one ofthe conductors 127-127 (FIG. 20) which is subsequently solderedtherewith.

Each of the contactors 124-124 are formed with a rearward, angled tab167 which is contiguous with and extends rearwardly from the short tine161. An intermediate portion of the long tine 159 of each of thecontactors [24-124 is formed with an intermediate ramp 173 and theforward end of the short tine 161 is formed with a hooked ramp 174. Eachof the contactors 124-124 are formed with a locking tab 175 whichextends outwardly from a portion of the edge of the short tine 161adjacent to the pocket 172.

When the contactors 124-124 are assembled within the associated cells154-154 (FIG. of the stacked wafers 122- 122, the hooked ramp 174 ofeach of the contactors is biased into a depression formed by thetransverse undercut 136 and the upwardly sloped surface 137 whichprecludes rearward movement of the contactors unless the hooked ramp isbiased upwardly out of the depression by some external means such as theneedlelike implement previously mentioned. in addition, the rearward tab167 of each of the contactors 124-124 engages the sloped surface 134 ofthe associated cells 154 154 to preclude continued forward movement ofthe contactors into the associated cells. As the contactors 124-124 aremoved into the associated cells 154-154, the locking tab 175 of each ofthe contactors is moved into the contactor-locking groove 145 of each ofthe associated cells to prevent movement of the contactors out of thelongitudinal opening of the associated slot 131 during periods when hewafers 122-122 are unstacked. In this manner, the contactors 124-124 areprecluded from moving out of the associated cells 154-154 in anydirection regardless of whether the wafers 122- 122 are stacked orunstacked.

Referring to FIG. 24, there is illustrated the side wafer 128 which isformed at opposite ends thereof with through-notches 143 and 144. Akeyway 150 is formed along one edge of one flat surface 155 of the sidewafer 128 adjacent to the throughnotch 143. A projection 146 extendsoutwardly from the flat surface 155 of the side wafer 128. A L-shapedslot 181 is formed centrally in two contiguous edges of the projection146 of the side wafer 128. The projection 146 of the side wafer 128 isfurther formed with a pair of openings 182 and 183 which facilitatehandling of the stacked wafers 122-122 and the side wafers 128 and 129during assembly and disassembly of the coupler unit 121 with the outerband 125 and also reduces undesirable heat sink effects. The side wafer128 is assembled with one side of the stack of laminated wafers 122-122so that the keeper lugs 138 and 139 (FIG. 21) of the adjacent wafer fitinto the keeper notches 143 and 144, respectively, of the side wafer. Inaddition, a flat surface 160 of the wafer 128 is positioned over theslots 131-131 (FIG. 20) of the adjacent wafer 122 to form thecontactor-receiver cells 154 -154.

Referring to FIG. 25, there is illustrated the side wafer 128 having apair of projecting keeper lugs 149 and 151 which extend from oppositeends of a flat surface 184 of the side wafer. A projection 152 extendsfrom another flat surface 186 of the side wafer 129 and is formedcentrally with a L-shaped slot 187 in two contiguous edges thereof. Theprojection 152 of the side wafer 129 is also formed with a pair ofopenings 188 and 189 to reduce undesirable heat sink effects and tofacilitate handling of the side wafer and the coupling unit 121 aspreviously described. The side wafer 129 is assembled with one side ofthe stack of laminated wafers 122-122 (FIG. 20) so that the keeper lugs149 and 151 fit into the keeper notches 141 and 142, respectively, ofthe adjacent wafer.

Referring now to FIG. 26, there is illustrated the inner band 123 whichis composed of a sleevelike, four-sided structure having a centralopening 191. One edge of each side of the inner band 123 is formed withtwo adjacent rows, designated generally by the numerals 192 and 193, oftapered teeth 194- 194 which extend from associated edges of the bandand generally in the plane of the edge. The teeth 194-194 of each of therows 192 and 193 are spaced from the adjacent teeth in the same row andthe teeth of one row are aligned with the space between the teeth" ofthe adjacent row. Cutaways 196 and 197 are formed in edges of twoopposite sides of the band 123 with separation notches 198 and 199,respectively, formed centrally in the cutaways. The inner band 123 isformed with a key 201 in one inner comer thereof and is formed withakeyway 202-in an outer comer thereof adjacent to the key.'

The wafers 122-122 and the side wafers 128 and 129 are assembled in astack, for example, in the same manner as the coupler unit 21 (FIG. 2)is assembled, to form the contactorreceiving cells 154-154. Thereafter,the contactors 124- 124, with associated conductors 127-127 assembledtherewith, may be inserted into the associated cells 154-154. However,the conductors 127-127 could be inserted into he associated cells154-154 after the assembled, stacked wafers 122-122 and side wafers 128and 129 have been inserted into the inner band 123.

The stacked wafers 122-122 and side wafers 128 and 129 are insertedsnugly into the opening 191 of the inner band 123 so that the long tine159 of each of the contactors 124-124;

which are assembled within the associated cells 154-154, are parallelwith and project in the same general direction as the teeth 194-194 ofthe inner band. In addition, the keyway 150 of the side wafer 128 slidesover and is guided by the key 210 formed in one inner corner of theinner band 123.

As illustrated in FIG. 20, base portions of the projections 146 and 152of the side wafers 128 and 129, respectively, are positioned in, and theremaining portions of the projections extend from, the cutaways 196 and197, respectively, of the inner band 123. The tip ends of the teeth194-194 extend slightly beyond the tip ends of the long tines 159-159 ofthe contactors 124-124 to provide protection for the contactors from anyextraneous lateral forces.

As further illustrated in FIG. 20, when one coupler unit 121 isassembled with a mating coupler unit, the tapered, spaced teeth 194-194of one of the inner bands 123-123 mesh into the associated spacesbetween the teeth of the mating inner band. Thus, the rows 192-192 and193-193 of the teeth 194-194 of the mating coupler units 121-121intermesh and overlay to absorb the inadvertent side pressures andsafeguard the contactors 124-124 of the mating coupler units duringclosure of the mating units.

When the stacked wafers 122-122 and side wafers 128 and 129 areassembled within the inner band 123, base portions of the projections146 and 152, which are positioned in the eutaways 196 and 197,respectively, of the inner band, cover the open side of each of theseparation notches 198 and 199, respectively. If the stacked wafers122-122 and side wafers 128 and 129, which are fitted tightly within theinner band 123, are to be removed from within the inner band, flatimplements (not shown) are placed into the slots 198 and 199. The flatimplements are then turned to separate the projections 146 and 152 fromthe slots 198 and 199, respectively, and thereby move the stacked wafers122-122 and side wafers 128 and 129 partially out of the inner band 123.The projections 146 and 152 of the side wafers 128 and 129,respectively, of each coupler unit 121 can then be gripped manually inthe areas of the side wafer openings 182, 183 and 188, 189,respectively, to withdraw the wafers 122-122 and side wafers completelyfrom within the inner band 123.

Referring to FIG. 27, there is illustrated the outer band consisting ofa rectangular, tubular structure having a central opening 203. A key 204is formed in a portion of one inner comer of the outer band 125 andextends from one edge of the band to an intermediate portion thereof.Another key 206 is formed in an adjacent inner comer of the outer band125 and extends from the opposite edge of he band to an intermediateportion thereof. Cutaways 207-207 are formed in opposite edges ofopposed walls of the outer band 125. Each of the eutaways 207-207 areformed with a pair of separation notches 208-208 which are spaced apartby a raised surface 209.

The outer band 125 is formed with a pair of slots 210-210 for receivingnd supporting for rotation therein a pair of keeper springs, designatedgenerally by the numeral 211. Each of the keeper springs 211-211 isformed with a sank portion 212 and eyeletted ends 213-213. Intermediateportions of the shank portions 212-212 of the keeper springs 211-211 canbe inserted into the associated slots 210-210 of the outer band 125 bymoving the walls of the band, which include the slots, inwardly towardeach other so that the mouth of each of the slots is openedsubstantially. The shank portions 212-212 of the keeper springs 211-211are then inserted into the associated open slots 210-210 and the outerband 125 is released so that the keeper springs are captured within theassociated slots but are free to rotate and slide therewithin. Theeyeletted ends 213-213 of each of the keeper springs 211- 211 extendoutwardly from associated raised surfaces 209- 209 of the outer band125.

As an alternative, the keeper springs 211-211 can be molded with theouter band 125 but should be pretreated with a cadmium plating and amold release compound so that the keeper springs are permitted to rotateand slide freely within their molded confinement.

After the coupler units 121-121 have been formed, mating coupler units,including the associated bands 123-123, can be inserted into oppositesides of the outer band 125 as shown in FIG. 20. However, prior to theinserting of the coupler units 121-121 into the outer band 125, thekeeper springs 211- 211 of the outer bands 125-125 must be turnedpartially so that the associated eyeletted ends 213-213 extend outwardlyfrom the side of the band and clear of the path of the coupler unitsduring the inserting of the units into the outer band. The coupler units121-121 are then inserted snugly into the associated outer band 125 butnot s snugly as the fit of the wafers 122-122 and side wafers 128 and129 within the associated inner band 123. As the mating coupler units121- 121 are inserted into the outer band 125, the keyway 202 of theinner band 123 of oner coupler unit slides over the key 204 of the outerband and the keyway of the inner band of the mating coupler unit slidesover the key 206 of the outer band. As the two mating coupler units121-121 are moved together within the outer band 125, the teeth 194-194of the inner bands 123-123 of the mating coupler units intermesh andabsorb the forces being exerted upon the coupler units during the matingassembly thereof. As the teeth 194-194 of the associated inner bands123-123 of the mating coupler units 121-121 intermesh, the contactors124-124 of the mating coupler units are moved into contacting engagementas shown in FIG. 20 and as previously described with respect to FIG. 18.

As the mating coupler units 121-121 are moved into the assembledrelation within the outer band 125, end portions of the projections146-146 and 152-152 of the side wafers 128-128 and 129-129,respectively, are moved into associated ones of the cutaways 207-207formed in the outer band. In addition, the slots 181-181 and 187-187 ofthe wafers 128-128 nd 129-129, respectively, move over adjacent portionsof the shank portions 212-212 of the associated keeper springs 211-211until one end of each of the projections engages an associated one ofthe raised surfaces 209-209 in the cutaways 207-207 of the outer band125. The end portion of the mating coupler units 121-121 having theassociated conductors 127-127 extending therefrom is then flush with theassociated edge portions of the outer band 125.

In addition, a small opening is formed where the projections 146-146 and152-152 of the side wafers 128-128 and 129-129, respectively arepositioned adjacent to associated ones of the separation notches 208-208of the outer band 125. Thereafter, the keeper springs 211-211 arerotated par tially so that the eyeletted ends 213-213 of the rods arebiased into associated keeper recess portions of the slots 181-181 and187-187 of the side wafers 128-128 and 129-129, respectively, to latchthe mating assembled coupler units 121-121 within the outer band 125 toform the coupler 120 as shown in FIG. 20.

Referring to FIG. 28, there is illustrated a shipping cover, designatedgenerally by the numeral 214, which is composed of an insulatingmaterial and has a substantially flat portion 215 with a centrallyupstanding finger grip and latching wall 216. The latching wall 216 isformed with a pair of keeper depressions 217-217 along the edge ofopposite, outer comer portions thereof. Side portions 218-218 extenddownwardly from the edges of the flat portion 214 to form an innerenclosure 219 with the underside of the flat portion 215.

Keyways 221-221 are formed in each of the four outer corners of the sideportions 218-218. Cutaway portions 222- 222 are formed in the sides ofeach of the side portions 218- 218 of the shipping cover 213 and are cutaway at a depth which is equal to twice the thickness of one of theteeth 194- 194 of the inner band 123.

Prior to shipping the cable 26 (FIG. 1), and after the coupler units121-121, which are assembled with the cable, have been inserted into oneend of associated ones of the outer bands 125-125, one of the shippingcovers 214-214 is then inserted into the other end of each of the outerbands which is shown partially in phantom view in FIG. 28. Dependingupon which end of the outer band 125 the associated coupler unit 121 isinserted into, one of the corner keyways 221-221 of the shipping cover214 moves over the key 204 or the key 206 of the associated outer bandwhen the cover is inserted into the band. In addition, the cutawayportions 222-222 of the side portions 218-218 of the shipping cover 214are positioned over the extended ends of the plurality of teeth 194- 194of the rows 192 and 193 of the teeth of the associated inner band 123which is also shown partially in phantom view in FIG. 28.

The inner enclosure 219 of the cover 214 is positioned protectively overand spaced from the extended ends of the long ties 159-159 of thecontactors 124-124. The free-end edges of the side portions 218-218 ofthe covers 214-214 rest on the flush outer surface of the associatedcoupler unit 121 to facilitate the complete enclosure of the extendedend portions of the long tines 159-159 of the contactors 124-124.

When the shipping covers 214-214 have been properly inserted into theopen end of the associated ones of the outer bands -125, the latchingwall 216 of each cover is positioned so that the keeper depressions217-217 are positioned adjacent to the eyeletted ends 213-213 of theassociated keeper springs 211-211. The keeper springs 211-211 are thenrotated partially to position one of the eyeletted ends 213-213 of eachof the keeper springs into an associated one of the keeper depressions217-217 formed in the latching wall 216 of the shipping cover 214. Inaddition, as the keeper springs 211-211 are rotated partially, theeyeletted ends 213-213 at the opposite ends of the rods are moved intothe associated slots 181 and 187 of the side wafers I28 and 129,respectively, of the coupler unit 121 as shown in the upper portion ofFIG. 20. Each of the shipping covers 214-214 is now latched with theassociated coupler unit 121 and the associated outer band 125 andprotects the contactors 124- 124 of the associated coupler unit duringshipment of the assembly to another location.

What is claimed is:

1. An electrical coupler for connecting color-coded conductors, whichcomprises:

a pair of mating, identical coupler units,

each unit including a plurality of different colored, laminate wafersstacked in a selected color-coded pattern having colors corresponding tothe colors of insulation of the conductors, the stacked wafers formingcontactor-receiving cells within each wafer, and

a plurality of contactors within the respective cells, the contactorshaving a corresponding plurality of the colorcoded conductors securedtherewith, each color-coded conductor having insulation of a given colorsecured to a contactor occupying the cell formed by the wafer of thesame given color, so that when the coupler units are brought together,the colored wafers of one unit are aligned with the mating wafers of thesame colors and the color-coded conductor groups secured to one couplerunit are connected to corresponding color-coded conductor groups securedto the mating coupler unit.

2. An electrical coupler as set forth in claim 1 which includes:

each wafer being formed with at least one slot having opposed spacedsidewalls,

the slots of the stacked wafers forming the contactor-receiving cells,

one sidewall of each slot of the wafers being formed with acontactor-locking groove, and

a tab formed on each contactor and positioned so that the tab isinserted into the contactor-locking groove when the contactor isinserted into the associated cell of the coupler unit to precludemovement of the contactor out of the longitudinal opening of theassociated slot during a period when the wafers are unstacked.

3. The electrical coupler as set forth in the claim 1 which includes:

a pair of resilient inner bands for receiving therewithin associatedstacks of the laminated wafers which are keyed and supported in anassembled relation.

4. The electrical c'oupler as set forth in claim 3 which includes:

each of the contactors being formed with long tines which extend fromassociated cells of the associated coupler unit, and

the resilient inner bands being formed with means for protecting endportions of the long tines of the contactors which extend fromassociated cells.

5. The electrical coupler as set forth in claim 4 wherein the means forprotecting the long tines of the contactors includes:

at least a pair of rows of spaced teeth which extend from one edge ofthe resilient inner bands in a direction parallel with the direction ofextension of the long tines of the contactors with the ends of the teethextending a distance beyond the ends of the long tines so that thecontactor ends of the long tines are protected from lateral forces andso that the spaced teeth of the inner bands of each coupler unitintermesh with the spaced teeth of the mating coupler unit and absorbpressures exerted upon the coupler unit when the units are assembledtogether.

6. The electrical coupler as set forth in claim 3 which includes:

a resilient outer band for receiving within opposite ends the matingidentical coupler units including the stacked wafers and the associatedinner bands which are keyed in a position so that the contactors of eachcoupler unit are held in contacting engagement with the contactors ofthe mating coupler unit.

7. The electrical coupler unit as set forth in claim 6 wherein theresilient outer band includes latching means for locking the assembledmating coupler units within the outer band.

8. The electrical coupler as set forth in claim 7 wherein the means forlatching the coupler units within the outer band includes:

a pair of springs having shank portions attached to the outer band formovement relative to the band, and

the ends of the springs being deformed structurally to fit intoassociated complementary portions of the coupler units after the couplerunits have been assembled within the outer band so that the couplerunits are locked within the outer band.

9. An electrical coupler for connecting color-coded conductors, whichcomprises:

a pair of identical mating coupler units,

each unit including a plurality of different colored, laminate wafershaving colors corresponding to the colors of insulation of theconductors, the wafers being stacked in a selected color-coded patternand having contactorreceiving cells therein, and

a plurality of contactors within the respective cells, pairs of thecontactors having color-coded pairs of conductors secured therewith, atleast one conductor of each conductor pair having colored insulation ofcolor corresponding to one of the wafer colors, each of the conductorshaving insulation of a wafer color being secured to the contactor whichoccupies one of the cells formed by the wafer of the same color, theother conductor of the conductor pair being secured with a contactorwhich occupies the adjacent cell formed by the same wafer, so that whenthe coupler units are brought together the colored wafers of one unitare aligned with the mating wafers of the same colors and the colorcoded pairs of conductors of one coupler unit are connected to theidentically colorcoded pairs of the mating coupler unit.

10. An electrical coupler for connecting color-coded conductors, whichcomprises:

a pair of mating, identical coupler units,

each unit including a plurality of stacked laminate wafers of differentcolors corresponding to the colors of insulation of the conductors, eachwafer having a series of parallel, spaced slots formed on one surfacethereof and a flat face formed on the opposite surface thereof, thelaminate wafers formed with complementary interlocking structure topreclude relative lateral movement, the stacked laminate wafers beingassembled in a predetermined color-code arrangement, whereby the groovesof one wafer are positioned adjacent the flat face of an adjacent waferto form a plurality of contactor-receiving cells,

a plurality of contactors within the cells of each coupler unit, thecontactors formed with tines which extend from the assembly and arereceived by cells of the mating identical coupler unit, the contactorsprovided with a pocket for receiving conductors having different coloredinsulation thereon, whereby the colors of the insulation correspond tothe different colors of the laminate sections of the coupler unit sothat the conductors having a given colored insulation may be attached tocontactors inserted into one of the cells formed by the laminate waferof the same color,

a resilient band for receiving within opposite ends the mating,identical coupler units, and

means formed in the band for keying the coupler units in an assembledrelation within the band so that the colored wafers of one unit arealigned with the mating wafers of the same colors and the color-codedconductors of one coupler unit are connected to correspondingcolor-coded conductors of the mating coupler unit.

11. An electrical coupler for connecting color-coded conductors, whichcomprises:

a pair of identical, mating coupler units,

each unit including a plurality of different colored wafers formed froma first group of colors, the wafers being stacked in a selectedcolor-coded pattern and having a row of contactor-receiving cells withineach wafer, and

a plurality of contactors within the respective cells of the couplerunit, a plurality of pairs of the contactors secured with a plurality ofpairs of conductors, one conductor of each pair having coloredinsulation with a color of the first group, the other conductor of eachpair having colored insulation with a color of the second group, theconductors having insulation color of the first group secured withcontactors occupying cells formed by the wafer of the same color, theconductors having insulation color of the second group secured withcontactors occupying the adjacent cells formed by the same wafer, sothat when the coupler units are brought together the colored wafers ofone unit are aligned with the mating wafers of the same colors and thecolor-coded pairs of conductors of one coupler unit are connected to theidentically colorcoded pairs of the other coupler unit.

12. An electrical coupler for connecting color-coded conductors, whichcomprises:

a pair of identical, mating coupler units,

each unit including a plurality of different colored wafers formed froma first group of colors which corresponds to a first of two groups ofcolors of insulation of the conductors, the wafers being stacked in aselected color-coded pattern, each of the stacked wafers forming a rowof contactor-receiving cells, the cells of the stacked wafers formingcolumns of cells perpendicularly disposed from the rows ofcells, and

a plurality of contactors within the respective cells, a plurality ofpairs of the contactors secured with a plurality of color-coded pairs ofconductors, a first conductor of each

1. An electrical coupler for connecting color-coded conductors, whichcomprises: a pair of mating, identical coupler units, each unitincluding a plurality of different colored, laminate wafers stacked in aselected color-coded pattern having colors corresponding to the colorsof insulation of the conductors, the stacked wafers formingcontactor-receiving cells within each wafer, and a plurality ofcontactors within the respective cells, the contactors having acorresponding plurality of the color-coded conductors secured therewith,each color-coded conductor having insulation of a given color secured toa contactor occupying the cell formed by the wafer of the same givencolor, so that when the coupler units are brought together, the coloredwafers of one unit are aligned with the mating wafers of the same colorsand the color-coded conductor groups secured to one coupler unit aReconnected to corresponding color-coded conductor groups secured to themating coupler unit.
 2. An electrical coupler as set forth in claim 1which includes: each wafer being formed with at least one slot havingopposed spaced sidewalls, the slots of the stacked wafers forming thecontactor-receiving cells, one sidewall of each slot of the wafers beingformed with a contactor-locking groove, and a tab formed on eachcontactor and positioned so that the tab is inserted into thecontactor-locking groove when the contactor is inserted into theassociated cell of the coupler unit to preclude movement of thecontactor out of the longitudinal opening of the associated slot duringa period when the wafers are unstacked.
 3. The electrical coupler as setforth in the claim 1 which includes: a pair of resilient inner bands forreceiving therewithin associated stacks of the laminated wafers whichare keyed and supported in an assembled relation.
 4. The electricalcoupler as set forth in claim 3 which includes: each of the contactorsbeing formed with long tines which extend from associated cells of theassociated coupler unit, and the resilient inner bands being formed withmeans for protecting end portions of the long tines of the contactorswhich extend from associated cells.
 5. The electrical coupler as setforth in claim 4 wherein the means for protecting the long tines of thecontactors includes: at least a pair of rows of spaced teeth whichextend from one edge of the resilient inner bands in a directionparallel with the direction of extension of the long tines of thecontactors with the ends of the teeth extending a distance beyond theends of the long tines so that the contactor ends of the long tines areprotected from lateral forces and so that the spaced teeth of the innerbands of each coupler unit intermesh with the spaced teeth of the matingcoupler unit and absorb pressures exerted upon the coupler unit when theunits are assembled together.
 6. The electrical coupler as set forth inclaim 3 which includes: a resilient outer band for receiving withinopposite ends the mating identical coupler units including the stackedwafers and the associated inner bands which are keyed in a position sothat the contactors of each coupler unit are held in contactingengagement with the contactors of the mating coupler unit.
 7. Theelectrical coupler unit as set forth in claim 6 wherein the resilientouter band includes latching means for locking the assembled matingcoupler units within the outer band.
 8. The electrical coupler as setforth in claim 7 wherein the means for latching the coupler units withinthe outer band includes: a pair of springs having shank portionsattached to the outer band for movement relative to the band, and theends of the springs being deformed structurally to fit into associatedcomplementary portions of the coupler units after the coupler units havebeen assembled within the outer band so that the coupler units arelocked within the outer band.
 9. An electrical coupler for connectingcolor-coded conductors, which comprises: a pair of identical matingcoupler units, each unit including a plurality of different colored,laminate wafers having colors corresponding to the colors of insulationof the conductors, the wafers being stacked in a selected color-codedpattern and having contactor-receiving cells therein, and a plurality ofcontactors within the respective cells, pairs of the contactors havingcolor-coded pairs of conductors secured therewith, at least oneconductor of each conductor pair having colored insulation of colorcorresponding to one of the wafer colors, each of the conductors havinginsulation of a wafer color being secured to the contactor whichoccupies one of the cells formed by the wafer of the same color, theother conductor of the conductor pair being secured with a contactorwhich occupies the adjacent cell formed by the same wafeR, so that whenthe coupler units are brought together the colored wafers of one unitare aligned with the mating wafers of the same colors and the colorcoded pairs of conductors of one coupler unit are connected to theidentically color-coded pairs of the mating coupler unit.
 10. Anelectrical coupler for connecting color-coded conductors, whichcomprises: a pair of mating, identical coupler units, each unitincluding a plurality of stacked laminate wafers of different colorscorresponding to the colors of insulation of the conductors, each waferhaving a series of parallel, spaced slots formed on one surface thereofand a flat face formed on the opposite surface thereof, the laminatewafers formed with complementary interlocking structure to precluderelative lateral movement, the stacked laminate wafers being assembledin a predetermined color-code arrangement, whereby the grooves of onewafer are positioned adjacent the flat face of an adjacent wafer to forma plurality of contactor-receiving cells, a plurality of contactorswithin the cells of each coupler unit, the contactors formed with tineswhich extend from the assembly and are received by cells of the matingidentical coupler unit, the contactors provided with a pocket forreceiving conductors having different colored insulation thereon,whereby the colors of the insulation correspond to the different colorsof the laminate sections of the coupler unit so that the conductorshaving a given colored insulation may be attached to contactors insertedinto one of the cells formed by the laminate wafer of the same color, aresilient band for receiving within opposite ends the mating, identicalcoupler units, and means formed in the band for keying the coupler unitsin an assembled relation within the band so that the colored wafers ofone unit are aligned with the mating wafers of the same colors and thecolor-coded conductors of one coupler unit are connected tocorresponding color-coded conductors of the mating coupler unit.
 11. Anelectrical coupler for connecting color-coded conductors, whichcomprises: a pair of identical, mating coupler units, each unitincluding a plurality of different colored wafers formed from a firstgroup of colors, the wafers being stacked in a selected color-codedpattern and having a row of contactor-receiving cells within each wafer,and a plurality of contactors within the respective cells of the couplerunit, a plurality of pairs of the contactors secured with a plurality ofpairs of conductors, one conductor of each pair having coloredinsulation with a color of the first group, the other conductor of eachpair having colored insulation with a color of the second group, theconductors having insulation color of the first group secured withcontactors occupying cells formed by the wafer of the same color, theconductors having insulation color of the second group secured withcontactors occupying the adjacent cells formed by the same wafer, sothat when the coupler units are brought together the colored wafers ofone unit are aligned with the mating wafers of the same colors and thecolor-coded pairs of conductors of one coupler unit are connected to theidentically color-coded pairs of the other coupler unit.
 12. Anelectrical coupler for connecting color-coded conductors, whichcomprises: a pair of identical, mating coupler units, each unitincluding a plurality of different colored wafers formed from a firstgroup of colors which corresponds to a first of two groups of colors ofinsulation of the conductors, the wafers being stacked in a selectedcolor-coded pattern, each of the stacked wafers forming a row ofcontactor-receiving cells, the cells of the stacked wafers formingcolumns of cells perpendicularly disposed from the rows of cells, and aplurality of contactors within the respective cells, a plurality ofpairs of the contactors secured with a plurality of color-coded pairs ofconductors, a first conductor of eAch conductor pair having aninsulation color of the first of the two groups of colors, a secondconductor of each conductor pair having an insulation color of thesecond of the two groups of colors, the first conductor of the pairs ofconductors having insulation color of the first group secured withcontactors occupying alternate cells of the row of cells formed by thewafer of the same color, the second conductor of the pairs of conductorshaving insulation color of the second group of colors secured withcontactors occupying alternate columns of cells formed by cells notoccupied by the first contactors of each pair, so that when the couplerunits are brought together the colored wafers of one unit are alignedwith the mating wafers of the same colors and the color-coded pairs ofconductors of one coupler unit are connected to the identicallycolor-coded pairs of the other coupler unit.
 13. An electrical couplerfor connecting color-coded conductors, which comprises: a pair ofmating, identical coupler units, each unit including a plurality ofstacked laminate wafers of different colors, each wafer having a seriesof parallel, spaced slots formed on one surface thereof and a flat faceformed on the opposite surface thereof, the laminate wafers being formedwith complementary interlocking structure to preclude relative lateralmovement, the stacked laminate wafers being assembled in a predeterminedcolor-code arrangement so that the slots of one wafer are positionedadjacent the flat face of an adjacent wafer to form a plurality ofcontactor-receiving cells, each unit including a pair of differentcolored side wafers assembled on each stacked side of the stacked,laminate wafers, a plurality of contactors within the cells of eachcoupler unit, the contactors formed with tines which extend from theassembly and are received by cells of the mating, identical couplerunit, the contactors provided with a pocket for receiving conductors ofa unit cable of a multiple unit group, the conductors having differentcolored insulation thereon which corresponds to the different colors ofthe laminate sections of the coupler unit, the conductors having a givencolored insulation being secured with the contactors inserted into thecells formed by the wafer of the same color, the conductors of each unitcable being bound by a pair of different colored tapes having the samecolors as the colors of the side wafers, the colored tapes of each cableof the multiple group being a different color combination relative tothe tapes of the other cables of the group, so that the coupler unit ofthe color-coded conductors of one unit cable are distinguishable fromthe coupler unit of the conductors of another unit cable within themultiple unit group, and a resilient band for receiving within oppositeends the mating, identical coupler units, whereby the laminate wafers ofeach coupler unit are held in an assembled relation within the band andthe contactors of each coupler unit are held in contacting engagementwith the contactors of the mating coupler unit.
 14. An electricalcoupler, which comprises: a pair of mating, identical coupler units,each unit including a plurality of stacked laminate wafers, each waferhaving a series of parallel, spaced slots formed on one surface thereofand a flat face formed on the opposite surface thereof, the laminatewafers formed with complementary interlocking structure to precluderelative lateral movement, the stacked laminate wafers assembled so thatthe slots of one wafer are positioned adjacent the flat face of anadjacent wafer to form a plurality of contactor-receiving cells, aplurality of interchangeable contactors self-secured within the cells ofeach contactor-supporting coupler unit, the contactors formed with tineswhich extend from the unit and are received by cells of the mating,identical coupler unit, means formed on the contactors for receivingconductors secured therewith, means formed on each contactor forfacilitating the removal of the contactor from within the cell of thesupporting coupler unit so that the contactors and conductors securedtherewith may be interchanged relative to the coupler unit, and aresilient band for receiving within opposite ends the mating, identicalcoupler units whereby the laminate wafers of each coupler unit are keyedin an assembled relation and the contactors of each coupler unit areheld in contacting engagement with the contactors of the mating couplerunit.
 15. An electrical coupler, which comprises: a pair of mating,identical coupler units, each unit including a plurality of stackedlaminate wafers, each wafer having a series of parallel, spaced slotsformed on a first major surface thereof and a flat face formed on anopposite major surface thereof, each wafer formed with keeper lugs atopposite ends of the first major surface and keeper notches at oppositeends of the opposite major surface, the wafers stacked so that thekeeper lugs of each wafer fit into the keeper notches of the adjacentwafer to preclude relative lateral movement, the stacked laminate wafersassembled so that the slots of one wafer are positioned adjacent theflat face of an adjacent wafer to form a plurality ofcontactor-receiving cells, a plurality of contactors self-secured withinthe cells of each coupler unit, the contactors formed with tines whichextend from the assembly and are received by cells of the mating,identical coupler unit, means formed on the contactors for receivingconductors secured therewith, and a resilient band for receiving withinopposite ends the mating, identical coupler units whereby the laminatewafers of each coupler unit are keyed in an assembled relation and thecontactors of each coupler unit are held in contacting engagement withthe contactors of the mating coupler unit.
 16. An electrical coupler,which comprises: a pair of mating, identical coupler units, each unitincluding a plurality of stacked laminate wafers, each wafer having aseries of parallel, spaced slots formed on one surface thereof and aflat face formed on the opposite surface thereof, the laminate wafersformed with complementary interlocking structure to preclude relativelateral movement, the stacked laminate wafers assembled so that theslots of one wafer are positioned adjacent the flat face of an adjacentwafer to form a plurality of contactor-receiving cells, a plurality ofcontactors self-secured within the cells of each contactor-supportingcoupler unit, each of the contactors formed with a long tine whichextends from the unit and is received by one of the cells of the mating,identical coupler, each long tine formed with a ramp intermediate theends thereof positioned within the cell of the supporting unit, each ofthe contactors formed with a short time spaced from, and parallel with,the long tine, each short tine formed with a ramp on the leading endthereof positioned within the cell between the contactor end of thesupporting coupler unit and the long tine ramp, whereby the long tinesof each coupler unit are flexed and engaged by the ramps of therespective short and long tines of the mating coupler unit and areflexed into engagement with an intermediate portion of the respectivelong tines of the mating coupler unit, means formed on the contactorsfor receiving conductors secured therewith, and a resilient band forreceiving within opposite ends the mating, identical coupler unitswhereby the laminate wafers of each coupler unit are keyed in anassembled relation and the contactors of each coupler unit are held incontacting engagement with the contactors of the mating coupler unit.17. An electrical coupler, which comprises: a pair of mating, identicalcoupler units, each unit including a plurality of stacked laminatewafers, each wafer having a series of parallel, spaced slots formed onone surface thereof and a flat face formed on the oppositE surfacethereof, each of the slots formed with an undercut at one common end anda sloped surface at the opposite end, the laminate wafers formed withcomplementary interlocking structure to preclude relative lateralmovement, the stacked laminate wafers assembled so that the slots of onewafer are positioned adjacent the flat face of an adjacent wafer to forma plurality of contactor-receiving cells, a plurality of interchangeablecontactors positioned within the cells of each contactor-supportingcoupler unit, each of the contactors formed with a contacting end forengaging contactors of the mating coupler unit and a conductor-receivingend for receiving conductors secured therewith, each contactor formedwith a locking hook at the contacting end thereof which is flexed intoengagement with the slot undercut to preclude contactor movement towardthe conductor end of the contactor, each contactor formed with a tab atthe conductor end thereof which engages the sloped surface of the slotto preclude contactor movement toward the contacting end of thecontactor, whereby the contactors are self-secured within the cells ofthe coupler unit, each locking hook being accessible from the contactingend of the coupler unit so that the locking hook may be flexed fromengagement with the slot undercut and withdrawn from the cell of thestacked wafers to facilitate interchangeability of the contactors andthe conductors secured therewith, and a resilient band for receivingwithin opposite ends the mating, identical coupler units whereby thelaminate wafers of each coupler unit are keyed in an assembled relationand the contactors of each coupler unit are held in contactingengagement with the contactors of the mating coupler unit.
 18. Anelectrical coupler, which comprises: a pair of mating, identical couplerunits, each unit including a plurality of stacked laminate wafers, eachwafer having a series of parallel, spaced slots formed on one surfacethereof and a flat face formed on the opposite surface thereof, eachslot having a bed extending between opposed sidewalls, the laminatewafers formed with complementary interlocking structure to precluderelative lateral movement, the stacked laminate wafers assembled so thatthe slots of one wafer are positioned adjacent the flat face of theadjacent wafer to form a plurality of contactor-receiving cells, aplurality of contactors self-secured within the cells of eachcontactor-supporting coupler unit, each contactor formed with a pockethaving opposed sidewalls for receiving conductors secured therewith,each contactor formed with a long tine which integrally extends from onesidewall of the pocket toward a contacting end of the contactor, eachcontactor formed with a short tine which extends from the oppositesidewall of the pocket toward the contacting end of the contactor, thelong tine of each contactor flexed against a wall of the cell formed bythe flat face of he adjacent wafer, the short tine of each contactorflexed against the bed of the respective slot, whereby the tines areflexed apart to facilitate the reception and engagement of the contactorend of the long tine of the mating coupler unit with the long and shorttines of the supporting coupler unit, and a resilient band for receivingwithin opposite ends the mating, identical coupler units whereby thelaminate wafers of each coupler unit are keyed in an assembled relationand the contactors of each coupler unit are held in contactingengagement with the contactors of the mating coupler unit.
 19. Anelectrical coupler as set forth in claim 18, wherein: each of the longtines is formed with a ramp intermediate the ends thereof which ispositioned within the cell of the supporting coupler unit, each of theshort tines is formed with a ramp at the contactor end thereof which ispositioned within the cell of the supporting coupler, whereby the longtine of the mating coupler unit is flexed between, and engages, theramps and is flexed into engagement with an intermediate portions of thelong tine of the supporting coupler unit thereby facilitating multiplecontacting engagement between mating contactors of the mating couplerunits.
 20. An electrical coupler as set forth in claim 18, wherein: theslot beds of each wafer are formed with an undercut at one common endthereof and a sloped surface at the opposite end thereof, the contactorend of each short tine formed with a locking hook, and a tab angularlyextending from the conductor end of the pocket wall which is integralwith the short tine, the locking hook flexed into the slot undercut topreclude contactor movement toward the conductor end of the coupler unitand the angularly disposed tab being in engagement with the slopedsurface to preclude contactor movement toward the contactor end of thecoupler unit, whereby each contactor is removably self-secured withinone of the coupler unit cells.
 21. An electrical coupler unit forassembly with a mating coupler unit, which comprises: a plurality ofstacked laminate wafers, each wafer having at least one slot formed onone surface thereof, each slot having a bed extending between opposedsidewalls, the laminated wafers formed with complementary interlockingstructure to preclude relative lateral movement, the stacked wafersassembled so that the slot of each wafer is positioned adjacent to anassociated portion of a flat face of the adjacent wafer o form aconductor-receiving cell, a plurality of contactors self-secured withinthe cells of the coupler unit, each contactor formed with a pockethaving opposed sidewalls for receiving conductors secured therewith,each contactor formed with a long tine which extends integrally from onesidewall of the pocket toward a contacting end of the contactor, eachcontactor formed with a short tine which extends integrally from theopposite sidewall of the pocket toward the contacting end of thecontactor, the long tine of each contactor flexed against a wall of theassociated cell formed by the flat face of the adjacent wafer, the shorttine of each contactor flexed against the bed of the associated slot sothat the tines are flexed apart to facilitate the reception andengagement of the contactor end of the long tine extending from themating coupler unit, and a resilient band for receiving the stacked,laminate wafers within one end thereof with the wafers being keyed in anassembled relation and the contactors of the coupler unit held in aposition so that the long tines of the contactors can engage associatedcontactors of the mating coupler unit.
 22. An electrical coupler unit asset forth in claim 21, which includes: one sidewall of each slot of thewafers being formed with a contactor-locking groove, and a tab formed oneach contactor and positioned so that the tab is inserted into thecontactor-locking groove when the contactor is inserted into theassociated cell of the coupler unit to preclude movement of thecontactor out of the longitudinal opening of the associated slot duringa period when the wafers are unstacked.
 23. The electrical coupler unitas set forth in claim 21 wherein the resilient band includes: means forprotecting the contactor end portions of the long tines of thecontactors which extend from associated cells.
 24. The electricalcoupler unit as set forth in claim 23 wherein the means for protectingthe long tines of the contactors includes: at least a pair of rows ofspaced teeth which extend from one edge of the resilient band in adirection parallel with the direction of extension of the long tines ofthe contactors with the ends of the teeth extending a distance beyondthe ends of the long tines and the teeth of each row being positionedadjacent to an associated one of the spaces between the teeth of theadjacent row so that the contactor ends of the long ties are protectedfrom lateral forces.
 25. An electrical coupler, which comprises: a pairof mating, identical coupleR units, each unit including a plurality ofstacked laminate wafers, each wafer having at least one slot formed onone surface thereof, each slot having a bed extending between opposedsidewalls, the laminate wafers formed with complementary interlockingstructure to preclude relative lateral movement, the stacked laminatewafers assembled so that the slot of each wafer is positioned adjacentto a flat face of the adjacent wafer to form a contactor-receiving cell,a plurality of contactors self-secured within the cells of eachcontactor-supporting coupler unit, each contactor formed with a pockethaving opposed sidewalls for receiving conductors secured therewith,each contactor formed with a long tine which extends integrally from onesidewall of the pocket toward a contacting end of the contactor, eachcontactor formed with a short tine which extends integrally from theopposite sidewall of the pocket toward the contacting end of thecontactor, the long tine of each contactor flexed against a wall of thecell formed by the flat face of the adjacent wafer, the short tine ofeach contactor flexed against the bed of the respective slot, wherebythe ties are flexed apart to facilitate the reception and engagement ofthe contactor end of the long tine extending from the mating couplerunit, a pair of resilient inner bands for receiving therewithinassociated stacks of the laminated wafers which are keyed in anassembled relation, and a resilient outer band for receiving withinopposite ends the mating identical coupler units including the stackedwafers and the associated inner bands which are keyed in a position sothat the contactors of each coupler unit are held in contactingengagement with the contactors of the mating coupler unit.
 26. Anelectrical coupler as set forth in claim 25 which includes: one sidewallof each slot of the wafers being formed with a contactor-locking groove,and a tab formed on each contactor and positioned so that the tab isinserted into the contactor-locking groove when the contactor isinserted into the associated cell of the coupler unit to precludemovement of the contactor out of the longitudinal opening of theassociated slot during a period when the wafers are unstacked.
 27. Theelectrical coupler as set forth in claim 25 wherein each of theresilient inner bands includes: means for protecting the contactor endportions of the long tines of the contactors which extend fromassociated cells.
 28. The electrical coupler as set forth in claim 27wherein the means for protecting the long tines of the contactorsincludes: at least a pair of rows of spaced teeth which extend from oneedge of each of the resilient inner bands in a direction parallel withthe direction of extension of the long tines of the contactors with theends of the teeth extending a distance beyond the ends of the long tinesso that the contactor ends of the long tines are protected from lateralforces and so that the spaced teeth of the inner bands of each couplerunit intermesh with the spaced teeth of the mating coupler unit andabsorb pressures exerted upon the coupler unit when assembled within theouter band.
 29. The electrical coupler as set forth in claim 25 whereinthe resilient outer band includes latching means for locking theassembled mating coupler units within the outer band.
 30. The electricalcoupler as set forth in claim 29 wherein the means for latching thecoupler units within the outer band includes: a pair of keeper springshaving shank portions attached for movement to the outer band, and theends of the springs being deformed structurally to fit into associatedcomplementary portions of the coupler units after the coupler units havebeen assembled within the outer band so that the coupler units arelocked within the outer band.